Toyota Tercel 1984-1994 Repair Guide

Starter

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TESTING



See Figures 1 and 2

These tests must not be performed longer than 3-5 seconds to avoid burning out the coil.

Reduction Type
  1. Remove the starter from the vehicle.
  2.  
  3. Secure the starter solidly in an appropriate holding fixture.
  4.  
  5. Connect an ammeter in series with the positive ( + ) lead of a battery and terminal numbers 30 and 50 of the starter.
  6.  


CAUTION
DO NOT ground the positive leads against the starter or holding fixture! Starter damage and serious injury could result.

  1. Connect the negative (-) lead of a battery to the starter housing.
  2.  
  3. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows 90 amps or less of current.
  4.  



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Fig. Fig. 1: Connect the ammeter as shown on reduction type starters

Conventional Type
  1. Remove the starter from the vehicle.
  2.  
  3. Secure the starter solidly in an appropriate holding fixture.
  4.  
  5. Connect an ammeter in series with the positive ( + ) lead of a battery and both terminals at the starter.
  6.  


CAUTION
DO NOT ground the positive leads against the starter or holding fixture! Starter damage and serious injury could result.

  1. Connect the negative (-) lead of a battery to the starter housing.
  2.  
  3. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows 50 amps or less of current.
  4.  



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Fig. Fig. 2: On conventional type starters, connect the ammeter as shown

REMOVAL & INSTALLATION



See Figure 3


CAUTION
On models equipped with a Supplemental Restraint System (SRS) or "air bag,'' work must NOT be started until at least 90 seconds have passed from the time that both the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery.

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect all the wiring from the starter terminals. On some models, it may be necessary to remove the transaxle cable and bracket from the transaxle.
  4.  
  5. Remove the heat insulator, if equipped, and the starter mounting bolts.
  6.  
  7. Remove the starter.
  8.  
  9. Installation is the reverse of the removal procedure.
  10.  



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Fig. Fig. 3: Removing the starter from the vehicle

SOLENOID REPLACEMENT



See Figures 4, 5 and 6

The starter solenoid (magnetic switch) is an integral part of the reduction type starter. It cannot be replaced without partial disassembly of the starter. On the conventional type starter, the solenoid (magnetic switch) can be replaced without disassembly.

Reduction Type
  1. Remove the starter following the cautions and procedures described earlier.
  2.  
  3. Remove the nut connecting the lead wire from the magnetic switch terminal.
  4.  
  5. Remove the two through-bolts. Pull out the field frame assembly together with the armature from the magnetic switch.
  6.  
  7. Remove the two screws attaching the starter housing to the magnetic switch assembly.
  8.  
  9. Separate the starter housing together with the idler gear and clutch assembly from the magnetic switch.
  10.  

To install:
  1. Install the starter housing together with the idler gear and clutch assembly onto the magnetic switch.
  2.  
  3. Align the protrusion of the field frame with the groove of the magnetic switch.
  4.  
  5. Install the field frame assembly onto the magnetic switch. Secure the assembly with the two through-bolts.
  6.  
  7. Connect the lead wire to the magnetic switch terminal and install the nut.
  8.  
  9. Test the starter for proper operation.
  10.  
  11. Install the starter.
  12.  



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Fig. Fig. 4: Reduction type starter components



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Fig. Fig. 5: When installing the magnetic switch, make sure to engage the plunger stud underneath the drive lever

Conventional Type
  1. Remove the starter following the cautions and procedures described earlier.
  2.  
  3. Remove the nut connecting the lead wire from the magnetic switch terminal.
  4.  
  5. Loosen the two nuts holding the magnetic switch to the drive housing.
  6.  
  7. Lift the magnetic switch up and out to unhook the plunger from the drive lever.
  8.  

To install:
  1. Hook the plunger underneath the drive lever.
  2.  
  3. Install the two attaching nuts.
  4.  
  5. Install the magnetic switch lead wire and nut.
  6.  
  7. Test the starter for proper operation.
  8.  
  9. Install the starter.
  10.  



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Fig. Fig. 6: Conventional starter components

 
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